US20020158503A1 - Drum-type dual channel water-jet assisted cutting head - Google Patents
Drum-type dual channel water-jet assisted cutting head Download PDFInfo
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- US20020158503A1 US20020158503A1 US10/090,104 US9010402A US2002158503A1 US 20020158503 A1 US20020158503 A1 US 20020158503A1 US 9010402 A US9010402 A US 9010402A US 2002158503 A1 US2002158503 A1 US 2002158503A1
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- 238000005520 cutting process Methods 0.000 title claims abstract description 79
- 230000009977 dual effect Effects 0.000 title description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 69
- 239000012530 fluid Substances 0.000 claims abstract description 48
- 238000005065 mining Methods 0.000 claims abstract description 27
- 239000003245 coal Substances 0.000 claims description 25
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 19
- 239000011707 mineral Substances 0.000 claims description 19
- 230000001419 dependent effect Effects 0.000 claims description 4
- 230000035515 penetration Effects 0.000 abstract description 7
- 235000002505 Centaurea nigra Nutrition 0.000 abstract description 4
- 240000003323 Centaurea nigra Species 0.000 abstract description 4
- 238000000034 method Methods 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- 230000008901 benefit Effects 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 238000009412 basement excavation Methods 0.000 description 4
- 230000006872 improvement Effects 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 239000002817 coal dust Substances 0.000 description 2
- 238000009428 plumbing Methods 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
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- 230000008859 change Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
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Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21C—MINING OR QUARRYING
- E21C25/00—Cutting machines, i.e. for making slits approximately parallel or perpendicular to the seam
- E21C25/06—Machines slitting solely by one or more cutting rods or cutting drums which rotate, move through the seam, and may or may not reciprocate
- E21C25/10—Rods; Drums
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21C—MINING OR QUARRYING
- E21C25/00—Cutting machines, i.e. for making slits approximately parallel or perpendicular to the seam
- E21C25/60—Slitting by jets of water or other liquid
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21C—MINING OR QUARRYING
- E21C35/00—Details of, or accessories for, machines for slitting or completely freeing the mineral from the seam, not provided for in groups E21C25/00 - E21C33/00, E21C37/00 or E21C39/00
- E21C35/22—Equipment for preventing the formation of, or for removal of, dust
- E21C35/23—Distribution of spraying-fluids in rotating cutter-heads
Definitions
- the present invention generally pertains to mineral mining processes and, more particularly, but not by way of limitation, to a mining system particularly adapted for the recovery of coal from coal seams.
- Drum-type mining machines typically utilize a cutting head having a rotating cylinder or drum with a plurality of mechanical bits on an exterior surface for cutting into the mineral bearing material. The dislodged material is permitted to fall to the floor of the mining area, gathered up, and transported to the mining surface via conveyors or other transportation means.
- drum-type mining machines have proven effective, conventional drum-type cutting systems generally rely solely on a mechanical cutting action which subjects motors and bits to considerable wear and produces significant amounts of dust. Also, to increase the productivity of conventional mechanical cutting machines will normally require the installation of larger and heavier cutting motors on the miner to produce the additional power needed.
- the present invention overcomes the foregoing and other problems with a dual-channel water jet assisted, drum-type mining system which positions a plurality of high pressure water jets receiving water from a first channel to cut the mining face in two directions independently of mechanical bits, and positions a plurality of high pressure water jets receiving water from a second channel to allow sumping in another direction during downward shear.
- This combination of mechanical and hydraulic cutting results in higher rates of penetration and improved productivity.
- the high pressure water used in cutting may be pumped via a hose line or other conduit from a remote location. Alternatively, a high pressure water pump may be located on the chassis of the miner.
- the mining face is pre-scored by the water jets, the amount of wear on both the mechanical bits and the motors may be significantly reduced.
- FIG. 1 is a side elevational view of a drum-type cutting head contacting a mineral seam
- FIG. 2 is a simplified, top plan view of a drum-type mining system
- FIG. 3 a is a cutaway, side elevational view of a hard-head cutting head for drum-type mining systems
- FIG. 3 b is a cutaway, side elevational view of a ripper-chain cutting head for drum-type mining systems
- FIG. 4 is a side elevational view of a cutting drum with mechanical bits mounted on an exterior surface and showing an effective cutting diameter
- FIG. 5 is a front elevational view of a cutting drum showing a typical scrolling pattern to the bits
- FIG. 6 a is a side elevational view of a water jet assisted cutting head of the present invention showing a high pressure fluid conduit mounted tangentially above and below the drum;
- FIG. 6 b is a side elevational view of a water jet assisted cutting head of the present invention showing a high pressure fluid conduit shaped to fit between the exterior surface of the drum and the effective cutting diameter as defined by the mechanical bits;
- FIG. 7 is a top plan view of a hard-head embodiment of the water jet assisted cutting head of the present invention.
- FIG. 8 is a top plan view of a ripper-chain embodiment of the water jet assisted cutting head of the present invention.
- FIG. 9 a is a fragmentary, top plan view of an exemplary strut having two exemplary water conduits therein;
- FIG. 9 b is a side elevational cross-sectional view of a larger extent of the strut of FIG. 9 a taken along line 9 b - 9 b having an exemplary first water conduit therein;
- FIG. 9 c is a side elevational cross-sectional view of a larger extent of the strut of FIG. 9 a taken along line 9 c - 9 c having an exemplary second water conduit therein;
- FIG. 9 d is an enlarged, end elevational, partial cross-sectional view taken along line 9 d - 9 d of FIG. 9 a;
- FIG. 10 is an enlarged, side elevational cross-sectional view of exemplary water inlets for the first and second water conduits of FIGS. 9 b and 9 c;
- FIGS. 11 a - 11 b are side elevational views of the strut perimeter of FIGS. 9 b and 9 c with selected nozzles allowing high-pressure fluid therethrough;
- FIG. 12 is a schematic view of an exemplary flow system for the strut of FIG. 9 a .
- High-pressure water jets as described below, in conjunction with the water provided to the working area also have the significant benefit of greatly reducing the amount of coal dust liberated during the mining process.
- the amount and pressure of water provided to each of the water nozzles 185 may further be varied independently, depending on the specific application.
- FIGS. 1 - 11 b of the drawings like numerals being used for like and corresponding parts in each of the various drawings.
- drum-type continuous miners used for mining coal and other minerals
- high-pressure water jets the mechanical bits on a drum miner cut coal or contact the excavation point less than 50% of the circumference of the drum.
- the mechanical bits on a drum miner cut coal or contact the excavation point less than 50% of the circumference of the drum.
- less than half of the mechanical bits 105 on the drum-type cutting head 110 typically contact the cutting surface 25 at one time.
- the bits denoted by reference number 30 are in contact with and cutting the mining face 25 while the other bits 35 will not contact the mineral seam until the drum is rotated almost 180°. This also complicates the addition of water jets to the rotating drum 110 itself, and substantially reduces their effectiveness because, if mounted this way, at least half of the nozzles would be directed away from the mining face 25 at any one time.
- a simplified drum-type continuous miner 100 has a horizontal cylinder or drum 110 with its axis of rotation 111 perpendicular to the center line 55 of the opening or entry being developed 50 .
- the drum is turned in a top-forward direction of rotation 112 to achieve a cutting action with the mechanical bits, not shown.
- the drum 110 is generally moved up and down in a vertical plane, not shown, to increase the height of the opening 50 and overall production.
- the cylinder 110 is rotatably mounted to an arm or a boom 120 .
- the electric motors 130 to rotate the drum 110 may be mounted in the body of the miner, not shown, or the boom 120 , with the energy being transferred from the motors 130 to the drum 110 using either: (1) rotating drive shafts 140 housed within fixed supports 150 , as shown in FIG. 3A, or (2) gears 160 located behind and beneath a cutter or ripper chain 170 , seen in FIG. 3B, which wraps around the drum 110 , a central portion of which has gear-like teeth 175 for engaging the underside of the chain 170 , and an idler located on the support boom 120 .
- Either of these methods uses the rotating mechanical energy of an electric motor 130 to cause the drum 110 to rotate, top forward at a speed of approximately 60 revolutions per minute.
- the effective cutting diameter 115 as defined by the cutting bits 105 is greater than the diameter 116 of the smooth exterior surface of the drum 110 .
- This provides an off-set or distance 117 within which water jet nozzles and high pressure conduits may be mounted as in FIGS. 6A and 6B.
- the distance 117 may be calculated by subtracting the drum radius from the effective cutting radius. This distance 117 will typically range from about 3 to about 8 inches, but it is understood that this distance 117 is dependent only on the size of the drum 110 and the length of the bits 105 and bit blocks 107 selected and is not limited only to this particular range.
- mechanical bits 105 are typically attached to the smooth exterior surface of the drum 110 in positions that create various patterns as it rotates. This is referred to as the scroll 106 of the bits 105 .
- the spacing of the track, made by the mechanical bits 105 on the cutting surface 25 varies, depending on the longitudinal spacing of the mechanical bits 105 .
- the track spacing or bit lace spacing will be from about 1.5 to about 3 inches, or more.
- These mechanical bits 105 are removable. They are inserted in bit lugs or bit blocks 107 , which are in turn welded solidly to the exterior surface of the drum 110 . The mechanical bits 105 can be routinely removed from this bit lug 107 and replaced as they wear.
- the plumbing necessary to provide high-pressure water at sufficient flows to water jets can take advantage of the bit spacing or lacing, and the distance 117 between the smooth exterior surface of the drum 110 and the actual cutting diameter of the bits 105 .
- Water jets can be preferably mounted in two different ways.
- a first embodiment would involve the addition of a high pressure water hose, not shown, and metal piping 180 , which is run from the miner body or the boom 120 and mounted tangent to the upper and lower surfaces of the drum 110 .
- This piping 180 positioned within the effective cutting diameter 115 of the cutting head 110 , can actually extend beyond the center line of the cylinder 110 , so that the water jet nozzles 185 , are only slightly back from the mechanical bits 105 in contact with the mineral seam, not shown.
- a second embodiment would involve the addition of a high pressure water hose, not shown, and metal piping 180 , which is run from the miner body or the boom 120 and may be curved or shaped to fit about the circumference of and just beyond the smooth exterior surface of the drum 110 .
- the piping or conduits 180 are positioned within the effective cutting diameter 115 of the cutting head 110 , and can be tapped and fitted with nozzles 185 which are located between the surface of the drum 110 and the cutting face 25 of the material being mined.
- nozzles 185 are located between the surface of the drum 110 and the cutting face 25 of the material being mined.
- Either of these two exemplary embodiments would provide rigidly mounted high-pressure conduits 180 having water jet nozzles 185 at a very close distance to the solid coal being cut.
- the jet nozzles 185 provide high-pressure water which assists mining by cutting and creating a vertical slot or groove in the coal face from roof to floor as the drum 110 is moved up and down in a conventional cutting motion. These vertical grooves effectively pre-score the coal face and make it far easier for the mechanical bits 105 to then fracture the coal.
- an alternative method of mounting water jets 185 would involve running high-pressure water lines 180 at least partially within the existing support struts 150 of a hard-head miner, introduced in FIG. 3A.
- Various techniques are used to rotate the drum 110 .
- the support struts 150 are rigid, non-rotating members that may or may not contain drive shafts for rotating the cylinder 110 .
- the plumbing 180 can provide high-pressure water and sufficient flow to several water jets 185 mounted on the front, or core breaker edge 190 of these support struts 150 .
- These support struts 150 are non-rotating, while the actual segmented cylinder, or drum 110 , rotates on either side of the support strut 150 .
- these support struts 150 must be sufficiently wide to contain mechanical parts like a drive shaft, there is usually a zone of solid, uncut coal, referred to as a core, which forms between the two rotating drums 110 .
- the front edge 190 of the support strut 150 typically contains bits or sharp points 195 , see FIG. 3A, designed to break or cut the core, which remains between the two rotating cylinders.
- the high-pressure water jets 185 can be mounted in several positions on this core breaker 190 . This would also place the water jets 185 close to the surface being cut mechanically by the bits 105 . In this and other mounting applications, either fixed- or swivel-mounted (not shown) water-jets can be used.
- FIG. 8 in conjunction with FIG. 3B, a ripper-chain embodiment miner of the present invention is illustrated.
- the drum 110 is segmented or formed of three sections which are linked together by a spline, axle or other means to turn as a single unit about a common axis of rotation.
- the central section has gear-like teeth 175 , shown in FIG. 3B, which engage the underside of a ripper chain 170 .
- the chain 170 is looped around the drum 110 , and drive gears 160 . As the drive gears 160 turn, the chain 170 and the drum 110 are rotated top-forward to mine coal.
- the chain 170 and the outer sections of the drum 110 have mechanical bits on their exterior surfaces.
- rigid conduits 180 which are tapped to supply water nozzles 185 may be located above or below the cutting portions of the drum 110 or may be curved to fit completely around the drum 110 .
- the depicted embodiment has four conduits or tubes 180 around the drum 110 , it is understood that these rigid tubes 180 may be provided in any number which does not hinder the cutting drum 110 . If necessary, mechanical bits 105 may even be removed from the drum 100 to provide the lateral spacing required for mounting the high pressure conduits or tubes 180 .
- high-pressure water jets 185 to the drum-type continuous miner 100 allows additional hydraulic cutting power to be provided for the excavation of coal or other materials, beyond the power provided by the mechanical cutting head motors.
- This additional power is provided by high-pressure water pumps, not shown, which are powered by additional motors which may be located remotely from the continuous miner 100 .
- these high-pressure pumps could also be located on the continuous miner itself.
- the water jets 185 assist in the liberation of the coal from the working face.
- the high-pressure streams of water, which are produced by the water jets 185 actually penetrate and cut into the coal surface independent of and beyond the reach of the mechanical bits 105 .
- These slots, or grooves, cut by the high-pressure water jets 185 reduce the amount of energy required for mechanical excavation by pre-fracturing the coal and providing additional free faces for the coal to break as it is impacted by the mechanical bits 105 .
- the high-pressure water jets 185 and the water provided to the working area also have the significant benefit of greatly reducing the amount of coal dust liberated during the mining process.
- the amount and pressure of water provided to each of the water nozzles 185 may further be varied independently, depending on the specific application.
- Table 1 is provided to better illustrate how the use water jet assisted cutting on a drum-type miner may result in significant improvements in both penetration rate and production.
- a conventional drum-type miner in a ripper-chain configuration was first tested using mechanical cutting alone. The miner was then fitted with a water jet system according to the present invention. The water jets were supplied at about 6,000 psi and about 150-170 gallons per minute. Data from repeated trials were then averaged to produce Table 1. It is notable that the production with water jet assistance was nearly double that of the conventional mechanical bit drum-type miner.
- FIG. 9A there is shown a top plan view of an exemplary water jet assisted cutting head strut 900 of the present invention.
- FIGS. 9 B- 9 D show the strut 900 in more detail.
- FIG. 9B shows a side-elevational cross-sectional view of the water jet assisted cutting head strut 900 having a first high pressure fluid conduit 910 therein.
- the strut 900 may be shaped to fit between the exterior surface of the drum (not shown in this Figure) and the effective cutting diameter as defined by the mechanical bits. However, field testing has proved that the outer diameter of the strut 900 should be no closer than the outer edge of the mechanical bit block. If the strut 900 is closer than this, it will impede the cutting effectiveness of the mechanical bit.
- the fluid conduit 910 fluidly connects to a plurality of nozzles 920 positioned at a predetermined angle with respect to the conduit 910 .
- the nozzles 920 may secure to the conduit 910 via threads 930 and the like.
- the nozzles 920 are removable, and in certain embodiments the positioning of the nozzles 920 may be adjusted to change the angle of the nozzles 920 relative to the strut 900 depending on the mineral deposit height and hardness.
- FIG. 9C there is shown a side-elevational cross-sectional view of the strut 900 having a second internal fluid conduit 940 therein.
- the second fluid conduit 940 similarly fluidly connects with a plurality of nozzles 950 , which are alternately configured in either a first direction or a second direction.
- the number and directions of the nozzle configuration may be dependent on the height and hardness of mineral deposit to be cut and the approach of cutting, sumping, and shearing with the drum cutting head.
- the first fluid conduit 910 does not fluidly communicate with the second fluid conduit 940 , such that the nozzles 920 of the first fluid conduit 910 may allow fluid therethrough independently of the nozzles 950 of the second fluid conduit 940 .
- the nozzles 950 of the second fluid conduit 940 may be offset to avoid the first fluid conduit 910 in certain embodiments.
- FIG. 9D there is shown a side-elevational partial cross-sectional end view of the strut 900 of FIGS. 9 A- 9 C. Conduits 910 , 940 are shown traversing through the strut 900 .
- inlet connector 1000 in a side-elevational cross-sectional view.
- Inlet connector 1000 has respective inlets 1005 , 1010 for the first fluid conduit 910 and the second fluid conduit 940 respectively.
- the first fluid conduit 910 and the second fluid conduit 940 are separated from one another and are not fluidly connected.
- Threads 1020 may be provided at inlets 1005 , 1010 for connection to a fluid source (not shown).
- threads 1030 may be provided at a top portion 1040 and a bottom portion 1050 of the inlet connector 1000 for mechanically connecting the inlet connector 1000 to an external structure.
- FIGS. 11A and 11B there is shown side profile views of the strut 900 of FIGS. 9B and 9C.
- FIG. 11 a shows a first spray configuration wherein all nozzles 920 , 950 are allowing high-pressure fluid therethrough in the direction indicated by arrows 1100 , which may be referred to as sump mode.
- FIG. 11B shows a second spray configuration, referred to as shear mode, wherein high pressure fluid flows through the nozzles 920 in the direction indicated by arrows 1110 .
- the angles of the nozzles 920 , 950 may be adjusted, such as through the use of different nozzles, different coupling means, or through different positioning of the nozzles 920 , 950 .
- the fluid flow through the conduits may be controlled such that flow may be directed at certain angles with respect to the strut 900 and through desired nozzles only.
- FIG. 12 there is shown a schematic of a flow system 1200 for water jet assisted cutting head struts 900 .
- the struts 900 are transversely mounted to the drum 1210 .
- the struts 900 are fluidly connected to a manifold 1220 via fluid lines 1240 or the like.
- the manifold 1220 may contain the inlet connector 1000 (FIG. 10) for the respective strut 900 , or the inlet connector 1000 may be placed in a region near the drum 1210 or other suitable locations.
- a flow divider 1230 is provided to divide flow from a high pressure fluid source (not shown) through the manifold 1220 and into a respective fluid conduit 940 of a respective strut 900 .
- the manifold 1220 may be adapted to control fluid flow therethrough and into a respective strut 900 .
- strut 900 having dual fluid conduits can be described as follows: first, a preselected seam of mineral deposits is identified, and the cutting head having at least one strut 900 thereon is advanced toward the seam. High pressure fluid is passed through one or more conduits in the strut 900 and flows outwardly therefrom. The mechanical bits are actuated and engage the seam after the high pressure fluid has contacted the seam, which is referred herein as sumping. The cutting head is allowed to penetrate into the seam at least the distance about equal to 1 ⁇ 2 of the diameter of the cutting head.
- the cutting head is moved downwardly with respect to the seam while the high pressure fluid is adjusted to flow in shear-mode, wherein fluid flows only through one of the two conduits in the strut 900 .
- fluid flow is terminated and the miner backs up to allow cleaning of the floor, then advances back to the coal face. The cycle may then be repeated.
- the use of the dual channel water jet assisted cutting head provides significant advantages over cutting heads of prior systems.
- Table 2 is provided to better illustrate how the use of the dual channel jet assisted cutting on a drum-type miner may result in significant improvements in both penetration rate and production.
- conventional drum-type miner in a ripper-chain configuration was first tested using mechanical cutting alone. The miner was then fitted with a dual channel water jet system according to the present invention. The water jets were supplied at about 6,000 PSI and about 50-150 gallons per minute. TABLE 2 Penetration Flow Rate Production Technique (gpm) (ft/min) (tons/hour) Mechanical--no — 2.67 560 water assist--Six cutting bits removed
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Abstract
Description
- This application is a Continuation-In-Part of prior application Ser. No. 09/540,044 filed on Mar. 31, 2000, now pending.
- The present invention generally pertains to mineral mining processes and, more particularly, but not by way of limitation, to a mining system particularly adapted for the recovery of coal from coal seams.
- 2. History of the Related Art
- The recovery of coal, ore, or other material from mineral bearing strata or seams has been the subject of technological development for centuries. Among the more conventional mining techniques, drum-type mining systems have found industry acceptance. Drum-type mining machines typically utilize a cutting head having a rotating cylinder or drum with a plurality of mechanical bits on an exterior surface for cutting into the mineral bearing material. The dislodged material is permitted to fall to the floor of the mining area, gathered up, and transported to the mining surface via conveyors or other transportation means.
- Although drum-type mining machines have proven effective, conventional drum-type cutting systems generally rely solely on a mechanical cutting action which subjects motors and bits to considerable wear and produces significant amounts of dust. Also, to increase the productivity of conventional mechanical cutting machines will normally require the installation of larger and heavier cutting motors on the miner to produce the additional power needed.
- Thus, there is a need for a reliable mining system which addresses the limitations of the above-described conventional mining systems and which achieves higher rates of penetration and improved productivity.
- The present invention overcomes the foregoing and other problems with a dual-channel water jet assisted, drum-type mining system which positions a plurality of high pressure water jets receiving water from a first channel to cut the mining face in two directions independently of mechanical bits, and positions a plurality of high pressure water jets receiving water from a second channel to allow sumping in another direction during downward shear. This combination of mechanical and hydraulic cutting results in higher rates of penetration and improved productivity. The high pressure water used in cutting may be pumped via a hose line or other conduit from a remote location. Alternatively, a high pressure water pump may be located on the chassis of the miner. Of course, this means that the cutting motors on the drum-type miner itself can be much smaller than the motors used to generate equivalent production by conventional means. Moreover, because the mining face is pre-scored by the water jets, the amount of wear on both the mechanical bits and the motors may be significantly reduced.
- For a more complete understanding of the present invention, and for further objects and advantages thereof, reference is made to the following Detailed Description taken in conjunction with the accompanying drawings in which:
- FIG. 1 is a side elevational view of a drum-type cutting head contacting a mineral seam;
- FIG. 2 is a simplified, top plan view of a drum-type mining system;
- FIG. 3a is a cutaway, side elevational view of a hard-head cutting head for drum-type mining systems;
- FIG. 3b is a cutaway, side elevational view of a ripper-chain cutting head for drum-type mining systems;
- FIG. 4 is a side elevational view of a cutting drum with mechanical bits mounted on an exterior surface and showing an effective cutting diameter;
- FIG. 5 is a front elevational view of a cutting drum showing a typical scrolling pattern to the bits;
- FIG. 6a is a side elevational view of a water jet assisted cutting head of the present invention showing a high pressure fluid conduit mounted tangentially above and below the drum;
- FIG. 6b is a side elevational view of a water jet assisted cutting head of the present invention showing a high pressure fluid conduit shaped to fit between the exterior surface of the drum and the effective cutting diameter as defined by the mechanical bits;
- FIG. 7 is a top plan view of a hard-head embodiment of the water jet assisted cutting head of the present invention.
- FIG. 8 is a top plan view of a ripper-chain embodiment of the water jet assisted cutting head of the present invention.
- FIG. 9a is a fragmentary, top plan view of an exemplary strut having two exemplary water conduits therein;
- FIG. 9b is a side elevational cross-sectional view of a larger extent of the strut of FIG. 9a taken along line 9 b-9 b having an exemplary first water conduit therein;
- FIG. 9c is a side elevational cross-sectional view of a larger extent of the strut of FIG. 9a taken along line 9 c-9 c having an exemplary second water conduit therein;
- FIG. 9d is an enlarged, end elevational, partial cross-sectional view taken along line 9 d-9 d of FIG. 9a;
- FIG. 10 is an enlarged, side elevational cross-sectional view of exemplary water inlets for the first and second water conduits of FIGS. 9b and 9 c;
- FIGS. 11a-11 b are side elevational views of the strut perimeter of FIGS. 9b and 9 c with selected nozzles allowing high-pressure fluid therethrough; and
- FIG. 12 is a schematic view of an exemplary flow system for the strut of FIG. 9a.
- It has been discovered that the use of water-jet assistance during mining operations assist in the liberation of the coal from the working face of the mineral seam. The high-pressure streams of water actually penetrate and cut into the coal surface independent of and beyond the reach of the mechanical bits used during the drilling operation. These slots or grooves in the mineral face, cut by the high-pressure water jets, reduce the amount of energy required for mechanical excavation by pre-fracturing the coal and providing additional free faces for the coal to break as it is impacted by the mechanical bits. It has also been discovered that the use of multi-directional water-jets can aid in the pre-fracturing of the coal and mineral deposits. Such systems will be described in more detail below.
- High-pressure water jets as described below, in conjunction with the water provided to the working area also have the significant benefit of greatly reducing the amount of coal dust liberated during the mining process. The amount and pressure of water provided to each of the
water nozzles 185 may further be varied independently, depending on the specific application. - The preferred embodiment of the present invention and its advantages are best understood by referring to FIGS.1-11 b of the drawings, like numerals being used for like and corresponding parts in each of the various drawings.
- The mechanical cutting capabilities of drum-type continuous miners, used for mining coal and other minerals, can be supplemented by the inclusion of high-pressure water jets. Unlike borer-type miners where mechanical bits continuously contact the cutting face, the mechanical bits on a drum miner cut coal or contact the excavation point less than 50% of the circumference of the drum. As best seen in FIG. 1, less than half of the
mechanical bits 105 on the drum-type cutting head 110 typically contact the cuttingsurface 25 at one time. For example, the bits denoted byreference number 30 are in contact with and cutting themining face 25 while theother bits 35 will not contact the mineral seam until the drum is rotated almost 180°. This also complicates the addition of water jets to therotating drum 110 itself, and substantially reduces their effectiveness because, if mounted this way, at least half of the nozzles would be directed away from themining face 25 at any one time. - As best seen in FIG. 2, a simplified drum-type
continuous miner 100 has a horizontal cylinder or drum 110 with its axis ofrotation 111 perpendicular to thecenter line 55 of the opening or entry being developed 50. As theminer 100 is advanced toward themining face 25, the drum is turned in a top-forward direction ofrotation 112 to achieve a cutting action with the mechanical bits, not shown. Also, thedrum 110 is generally moved up and down in a vertical plane, not shown, to increase the height of theopening 50 and overall production. - With reference now to FIGS. 3a and 3 b together, the
cylinder 110 is rotatably mounted to an arm or aboom 120. Theelectric motors 130 to rotate thedrum 110 may be mounted in the body of the miner, not shown, or theboom 120, with the energy being transferred from themotors 130 to thedrum 110 using either: (1) rotatingdrive shafts 140 housed within fixedsupports 150, as shown in FIG. 3A, or (2) gears 160 located behind and beneath a cutter orripper chain 170, seen in FIG. 3B, which wraps around thedrum 110, a central portion of which has gear-like teeth 175 for engaging the underside of thechain 170, and an idler located on thesupport boom 120. Either of these methods uses the rotating mechanical energy of anelectric motor 130 to cause thedrum 110 to rotate, top forward at a speed of approximately 60 revolutions per minute. - As best seen in FIG. 4, the
effective cutting diameter 115 as defined by the cuttingbits 105 is greater than thediameter 116 of the smooth exterior surface of thedrum 110. This provides an off-set ordistance 117 within which water jet nozzles and high pressure conduits may be mounted as in FIGS. 6A and 6B. Thedistance 117 may be calculated by subtracting the drum radius from the effective cutting radius. Thisdistance 117 will typically range from about 3 to about 8 inches, but it is understood that thisdistance 117 is dependent only on the size of thedrum 110 and the length of thebits 105 and bit blocks 107 selected and is not limited only to this particular range. - As illustrated in FIG. 5,
mechanical bits 105 are typically attached to the smooth exterior surface of thedrum 110 in positions that create various patterns as it rotates. This is referred to as thescroll 106 of thebits 105. The spacing of the track, made by themechanical bits 105 on the cuttingsurface 25, varies, depending on the longitudinal spacing of themechanical bits 105. Typically, the track spacing or bit lace spacing will be from about 1.5 to about 3 inches, or more. Thesemechanical bits 105 are removable. They are inserted in bit lugs or bit blocks 107, which are in turn welded solidly to the exterior surface of thedrum 110. Themechanical bits 105 can be routinely removed from thisbit lug 107 and replaced as they wear. - The plumbing necessary to provide high-pressure water at sufficient flows to water jets can take advantage of the bit spacing or lacing, and the
distance 117 between the smooth exterior surface of thedrum 110 and the actual cutting diameter of thebits 105. Water jets can be preferably mounted in two different ways. - As shown in FIG. 6A, a first embodiment would involve the addition of a high pressure water hose, not shown, and
metal piping 180, which is run from the miner body or theboom 120 and mounted tangent to the upper and lower surfaces of thedrum 110. This piping 180, positioned within theeffective cutting diameter 115 of the cuttinghead 110, can actually extend beyond the center line of thecylinder 110, so that thewater jet nozzles 185, are only slightly back from themechanical bits 105 in contact with the mineral seam, not shown. - As illustrated in FIG. 6B, a second embodiment would involve the addition of a high pressure water hose, not shown, and
metal piping 180, which is run from the miner body or theboom 120 and may be curved or shaped to fit about the circumference of and just beyond the smooth exterior surface of thedrum 110. The piping orconduits 180 are positioned within theeffective cutting diameter 115 of the cuttinghead 110, and can be tapped and fitted withnozzles 185 which are located between the surface of thedrum 110 and the cuttingface 25 of the material being mined. Thus, the distance between thecoal face 25 and thenozzles 185 is effectively minimized. - Either of these two exemplary embodiments would provide rigidly mounted high-
pressure conduits 180 havingwater jet nozzles 185 at a very close distance to the solid coal being cut. The jet nozzles 185 provide high-pressure water which assists mining by cutting and creating a vertical slot or groove in the coal face from roof to floor as thedrum 110 is moved up and down in a conventional cutting motion. These vertical grooves effectively pre-score the coal face and make it far easier for themechanical bits 105 to then fracture the coal. - As shown in FIG. 7, an alternative method of mounting
water jets 185 would involve running high-pressure water lines 180 at least partially within the existing support struts 150 of a hard-head miner, introduced in FIG. 3A. Various techniques are used to rotate thedrum 110. The support struts 150 are rigid, non-rotating members that may or may not contain drive shafts for rotating thecylinder 110. Theplumbing 180 can provide high-pressure water and sufficient flow toseveral water jets 185 mounted on the front, orcore breaker edge 190 of these support struts 150. These support struts 150 are non-rotating, while the actual segmented cylinder, or drum 110, rotates on either side of thesupport strut 150. Since these support struts 150 must be sufficiently wide to contain mechanical parts like a drive shaft, there is usually a zone of solid, uncut coal, referred to as a core, which forms between the tworotating drums 110. Thefront edge 190 of thesupport strut 150 typically contains bits orsharp points 195, see FIG. 3A, designed to break or cut the core, which remains between the two rotating cylinders. The high-pressure water jets 185 can be mounted in several positions on thiscore breaker 190. This would also place thewater jets 185 close to the surface being cut mechanically by thebits 105. In this and other mounting applications, either fixed- or swivel-mounted (not shown) water-jets can be used. - Turning now to FIG. 8, in conjunction with FIG. 3B, a ripper-chain embodiment miner of the present invention is illustrated. The
drum 110 is segmented or formed of three sections which are linked together by a spline, axle or other means to turn as a single unit about a common axis of rotation. The central section has gear-like teeth 175, shown in FIG. 3B, which engage the underside of aripper chain 170. Thechain 170 is looped around thedrum 110, and drive gears 160. As the drive gears 160 turn, thechain 170 and thedrum 110 are rotated top-forward to mine coal. - As shown in FIG. 8, the
chain 170 and the outer sections of thedrum 110 have mechanical bits on their exterior surfaces. As shown in FIGS. 6A and 6B,rigid conduits 180 which are tapped to supplywater nozzles 185 may be located above or below the cutting portions of thedrum 110 or may be curved to fit completely around thedrum 110. Although the depicted embodiment has four conduits ortubes 180 around thedrum 110, it is understood that theserigid tubes 180 may be provided in any number which does not hinder the cuttingdrum 110. If necessary,mechanical bits 105 may even be removed from thedrum 100 to provide the lateral spacing required for mounting the high pressure conduits ortubes 180. - The application of high-
pressure water jets 185 to the drum-typecontinuous miner 100 allows additional hydraulic cutting power to be provided for the excavation of coal or other materials, beyond the power provided by the mechanical cutting head motors. This additional power is provided by high-pressure water pumps, not shown, which are powered by additional motors which may be located remotely from thecontinuous miner 100. Of course, if small enough, these high-pressure pumps, not shown, could also be located on the continuous miner itself. - The
water jets 185 assist in the liberation of the coal from the working face. The high-pressure streams of water, which are produced by thewater jets 185, actually penetrate and cut into the coal surface independent of and beyond the reach of themechanical bits 105. These slots, or grooves, cut by the high-pressure water jets 185 reduce the amount of energy required for mechanical excavation by pre-fracturing the coal and providing additional free faces for the coal to break as it is impacted by themechanical bits 105. - The high-
pressure water jets 185 and the water provided to the working area also have the significant benefit of greatly reducing the amount of coal dust liberated during the mining process. The amount and pressure of water provided to each of thewater nozzles 185 may further be varied independently, depending on the specific application. - By way of example only, Table 1 is provided to better illustrate how the use water jet assisted cutting on a drum-type miner may result in significant improvements in both penetration rate and production. For comparison purposes, a conventional drum-type miner in a ripper-chain configuration was first tested using mechanical cutting alone. The miner was then fitted with a water jet system according to the present invention. The water jets were supplied at about 6,000 psi and about 150-170 gallons per minute. Data from repeated trials were then averaged to produce Table 1. It is notable that the production with water jet assistance was nearly double that of the conventional mechanical bit drum-type miner.
TABLE 1 Penetration Production Cutting Motor Technique (ft/min) (tons/hour) (amps) Mechanical 1.00 227 125-130 Bits Only Mechanical + 1.83 415 100 Water Jets - Repeated tests were also made to determine the best configuration and orientation of
water jets 185. It was found that thewater jets 185 on asingle metal conduit 180 should focus cutting to produce a vertical groove or slot rather than random erosion of the entire face. - Referring now to FIG. 9A, there is shown a top plan view of an exemplary water jet assisted cutting
head strut 900 of the present invention. FIGS. 9B-9D show thestrut 900 in more detail. For example, FIG. 9B shows a side-elevational cross-sectional view of the water jet assisted cuttinghead strut 900 having a first highpressure fluid conduit 910 therein. Thestrut 900 may be shaped to fit between the exterior surface of the drum (not shown in this Figure) and the effective cutting diameter as defined by the mechanical bits. However, field testing has proved that the outer diameter of thestrut 900 should be no closer than the outer edge of the mechanical bit block. If thestrut 900 is closer than this, it will impede the cutting effectiveness of the mechanical bit. - As can be seen from FIG. 9B, the
fluid conduit 910 fluidly connects to a plurality ofnozzles 920 positioned at a predetermined angle with respect to theconduit 910. Thenozzles 920 may secure to theconduit 910 viathreads 930 and the like. Thenozzles 920 are removable, and in certain embodiments the positioning of thenozzles 920 may be adjusted to change the angle of thenozzles 920 relative to thestrut 900 depending on the mineral deposit height and hardness. - Referring now to FIG. 9C, there is shown a side-elevational cross-sectional view of the
strut 900 having a second internalfluid conduit 940 therein. The secondfluid conduit 940 similarly fluidly connects with a plurality ofnozzles 950, which are alternately configured in either a first direction or a second direction. The number and directions of the nozzle configuration may be dependent on the height and hardness of mineral deposit to be cut and the approach of cutting, sumping, and shearing with the drum cutting head. The firstfluid conduit 910 does not fluidly communicate with the secondfluid conduit 940, such that thenozzles 920 of the firstfluid conduit 910 may allow fluid therethrough independently of thenozzles 950 of the secondfluid conduit 940. Thenozzles 950 of the secondfluid conduit 940 may be offset to avoid the firstfluid conduit 910 in certain embodiments. - Referring now to FIG. 9D, there is shown a side-elevational partial cross-sectional end view of the
strut 900 of FIGS. 9A-9C.Conduits strut 900. - Referring now to FIG. 10, there is shown inlet connector1000 in a side-elevational cross-sectional view. Inlet connector 1000 has
respective inlets 1005, 1010 for the firstfluid conduit 910 and the secondfluid conduit 940 respectively. As can be seen in FIG. 10, the firstfluid conduit 910 and the secondfluid conduit 940 are separated from one another and are not fluidly connected.Threads 1020 may be provided atinlets 1005, 1010 for connection to a fluid source (not shown). Likewise,threads 1030 may be provided at atop portion 1040 and abottom portion 1050 of the inlet connector 1000 for mechanically connecting the inlet connector 1000 to an external structure. - Referring now to FIGS. 11A and 11B, there is shown side profile views of the
strut 900 of FIGS. 9B and 9C. - Different water-jet spray configurations are shown. For example, FIG. 11a shows a first spray configuration wherein all
nozzles arrows 1100, which may be referred to as sump mode. FIG. 11B shows a second spray configuration, referred to as shear mode, wherein high pressure fluid flows through thenozzles 920 in the direction indicated byarrows 1110. It is to be understood that the angles of thenozzles nozzles strut 900 and through desired nozzles only. - Referring now to FIG. 12, there is shown a schematic of a flow system1200 for water jet assisted cutting head struts 900. The
struts 900 are transversely mounted to thedrum 1210. Thestruts 900 are fluidly connected to amanifold 1220 viafluid lines 1240 or the like. The manifold 1220 may contain the inlet connector 1000 (FIG. 10) for therespective strut 900, or the inlet connector 1000 may be placed in a region near thedrum 1210 or other suitable locations. Aflow divider 1230 is provided to divide flow from a high pressure fluid source (not shown) through the manifold 1220 and into a respectivefluid conduit 940 of arespective strut 900. The manifold 1220 may be adapted to control fluid flow therethrough and into arespective strut 900. - The operation of
strut 900 having dual fluid conduits can be described as follows: first, a preselected seam of mineral deposits is identified, and the cutting head having at least onestrut 900 thereon is advanced toward the seam. High pressure fluid is passed through one or more conduits in thestrut 900 and flows outwardly therefrom. The mechanical bits are actuated and engage the seam after the high pressure fluid has contacted the seam, which is referred herein as sumping. The cutting head is allowed to penetrate into the seam at least the distance about equal to ½ of the diameter of the cutting head. Next, the cutting head is moved downwardly with respect to the seam while the high pressure fluid is adjusted to flow in shear-mode, wherein fluid flows only through one of the two conduits in thestrut 900. After reaching the base of the seam, fluid flow is terminated and the miner backs up to allow cleaning of the floor, then advances back to the coal face. The cycle may then be repeated. - The use of the dual channel water jet assisted cutting head provides significant advantages over cutting heads of prior systems. By way of example only, Table 2 is provided to better illustrate how the use of the dual channel jet assisted cutting on a drum-type miner may result in significant improvements in both penetration rate and production. For comparison purposes, conventional drum-type miner in a ripper-chain configuration was first tested using mechanical cutting alone. The miner was then fitted with a dual channel water jet system according to the present invention. The water jets were supplied at about 6,000 PSI and about 50-150 gallons per minute.
TABLE 2 Penetration Flow Rate Production Technique (gpm) (ft/min) (tons/hour) Mechanical--no — 2.67 560 water assist--Six cutting bits removed - As can be seen from Table 2, significant improvement is realized when nozzles from both conduits are actuated in phased-configurations (e.g. nozzles from both conduits are actuated simultaneously; only nozzles from one conduit are actuated). The size of the nozzles controls water flow and is likewise shown to affect production.
- It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description of a preferred embodiment. While the device shown is described as being preferred, it will be apparent to a person of ordinary skill in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention, as defined in the following claims. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein.
Claims (17)
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US10/090,104 US6755480B2 (en) | 2000-03-31 | 2002-02-27 | Drum-type dual channel water-jet assisted cutting head |
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US09/540,044 US6409276B1 (en) | 1999-04-02 | 2000-03-31 | Water-jet assisted drum-type mining system |
US10/090,104 US6755480B2 (en) | 2000-03-31 | 2002-02-27 | Drum-type dual channel water-jet assisted cutting head |
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EP1706585A1 (en) * | 2003-12-31 | 2006-10-04 | Kennametal, Inc. | Core breaker for an earth strata cutting assembly |
CN113266348A (en) * | 2021-06-24 | 2021-08-17 | 中国铁建重工集团股份有限公司 | Tunneling and anchoring all-in-one machine integrated with water jet system and construction method |
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CN117027810A (en) * | 2023-09-28 | 2023-11-10 | 长沙矿冶研究院有限责任公司 | Rotary jet type deep sea polymetallic nodule collecting apparatus |
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